Drogheda, Co.Louth, Ireland

Servicing

Call us now for a quote or a free review of your air system

CAC service ALL makes of air compressors, air dryers, compressed air-line systems and all ancillary equipment.

All CAC’s engineering staff have many years of experience in the compressed air field and have familiarized themselves with all safety procedures involved in the safe handling of pressurized vessels. You can download our safety manual here.

CAC engineers have been instructed by compressed air experts from U.S., U.K., Germany and Italy compressor manufacturers.

Service is normally engaged through the following methods:

Annual service contract

- Total maintenance programme

Fixed service price agreement

- Service on request

Urgent breakdown call-out

- Within 24 hours

Workshop repairs and service

- Reduces labour and travel time

Technical advice via phone or e-mail

- Free of charge

Long term compressor equipment hire

- Total responsibility contract

Compressed air pipe-work installations

- Specialists in Teseo aluminium
air-line

Compressed air auditing

- Major or minor

Air leak detection and repair

- During / after normal working hours

Supply of spare parts on request

- Featuring a unique returns policy

Energy or conservation advice

- Free of charge

TROUBLE SHOOTING

Burning smell from compressor (Compressor Overheating)

Check belts are not slipping

Check motor wiring is not loose or badly connected

Check electric cable size is correct

Check pressure switch wiring is correct

Check compressor pump is free from heavy dust

Check rotation is correct

Check compressor is well ventilated

Check non-return valve is not worn

Check electric motor is starting easily

Isolate the air compressor and ring CAC immediately at 041-9836923

Compressor not pumping

Check electric power is going to compressor

Check belts are not worn

Check for air leaks

Check ball valves are not switched to the “off” position

Check for burning smell

Check pressure on air gauge

Check in-take filters are not blocked

Check oil level is correct

Check pressure switch is in the “on” position

Isolate the air compressor and ring CAC immediately at 041-9836923

C.A.C. Ltd. supply all spare parts required for Fini air compressors for
service or repair. Just pop us an e-mail stating the Model No of your
air compressor and parts required and we’ll do the rest…

2- Compressed air lines should be identified (psi or bar) as to maximum working pressure.

3-Your emergency air cut-off valves should be located (as near as possible) to the working area.

4- Air hoses should be kept as clean as possible from dirt, grease and oil to prevent rapid deterioration.

5- Rubber air lines should not be allowed to be dragged across or left lying on your workshop floor where people can trip over them. Where possible, air lines should be installed at waist height or, better still, drop down from over-head Please see the AP Kit (Aluminium Pipe-Work) on our website for the best and most economical solution:http://www.compressedaircentre.com/product-category/ap-kit-aluminium-pipe-system

6- Flexible air lines should be secured in such a way that they cannot injure you should an air line bust or somehow break free and result in a dangerous “whipping” action.

8- Face or eye protection must be worn if you are using compressed air for cleaning any equipment.

9-Static electricity may be generated when you are using pneumatic tools. You must ensure these air tools are earthed if they are used where fuel, flammable vapours or other dangerous situations are known.

Important Safety Requirements For Using and Maintaining Your Compressed Air Equipment;

All air compressors and air systems should be inspected regularly by qualified and trained personnel. Please bear in mind the following critical points;

Air Receivers:

1- Never exceed the maximum recommended working pressure of you air receiver. Please notify your insurers of the fact that you use an air compressor. Your insurer may wish to inspect the air receiver. So, to avoid your equipment being prematurely condemned, please ensure you have purchased your compressed air equipment from a reputable supplier.http://www.compressedaircentre.com/product-category/air-receivers-tanks

2-Your insurance inspector may ask you to remove all pipes and gauges etc. on the air receiver so he can test and inspect it. Please make sure that you allow only experienced people involve themselves with any work to be carried out on a pressurised air vessel.

3- Your air receiver must be drained on a daily basis or install an automatic drain if you feel this task may be overlooked.

Note; if you install an auto drain, ensure you have visual access to the area where the moisture will be gathered in case the auto drain should ever fail. Visually check for evidence of drainage every week. Zero Air Loss Drain Valves are available and are more economical: http://www.compressedaircentre.com/product-category/air-receivers-tanks/

4- Air receivers should never be placed where they cannot be seen or easily maintained. They should be sited in such a way that the entire outside surfaces can be easily inspected.

5- Please remember, every compressor must have; an air gauge, a belt guard (if not directly driven), a safety valve (see our notes on safety/relief valves) and some method of pressure cut-out device. A bit obvious maybe but it’s surprising what some people will consider ‘adequate’!

Important; Stop valves or gate valves should never be installed between compressor pump and air receiver unless entirely necessary. If you must, it is very important that an adequate safety valve (capable of releasing the entire air produced by the compressor) is fitted between compressor and gate valve. This safety valve must be inspected annually for corrosion and a warning sticker should be attached to the stop valve stating:

Danger: For maintenance use only, do not touch.

Pressurised Air-Line Systems

1- Your air pipe-work supplier must provide you with a strong, durable efficiently designed air distribution system, capable of supplying adequate air supply to all productive areas. It should be specified to ensure you have no serious pressure drops anywhere that compressed air is required. Apart from the poor performance, it will cost you extra money on power if you have to increase the air pressure to obtain your desired working pressure.

2- All take off hoses should be checked regularly to ensure they don’t come loose or leak expensive compressed air.

3- All air lines, both flexible and rigid should be inspected at least once a month for air leaks or defects.

4- Ball valves (air cut-off valves) should be installed in the air line at various areas throughout the workshop or factory in order to isolate different parts of the factory without bringing total work/production to a halt (Teseo Aluminium Air-Line allows you to fit new “take-off” points in any part of your premises without the need to halt any production whatsoever).

5- Compressed air lines should clearly identify the maximum working pressure of the installed air system (see the sticker on the Teseo Aluminium Air-Line displayed on our website). http://www.compressedaircentre.com/product-category/teseo-aluminium-pipe-system/

6- It is highly recommended that you check for air leaks at least once a month. Choose a Saturday or non-working period so that you have a better chance of hearing major leaks. A good method of assessing you total air leakage is to go to your air compressor and fill it to maximum cut-out pressure; turn the compressor off from the main power supply, make a note of the final pressure, then look to see if the pressure is dropping on the air receiver gauge. It should not move because it is not in use but if it is slowly losing air pressure due to air leaks, repeat the topping up process and time it from cut-out pressure to 50 psi (or 4 bar).

Repair the leaks where possible then time the gauge differential again until you are satisfied you have repaired all air leaks. Repairing air leaks is the most cost effective time/money spent on your compressor, even more so than having a variable speed driven compressor (according to a German Survey).

7- Replace all old or corrosive air line with smooth bore aluminium pipework such as Teseo Aluminium Pipe-Work. An independent source has proven that the installation of Teseo Air-Line will reduce your power consumption by an average of 30%. The smooth bore dramatically reduces the friction of compressed air racing through the pipework (see our formula for selecting the correct size air-line in our ‘Compressor Manual’).

Pressure Regulators

Make sure you don’t allow any of anybody to adjust pressure regulators unless they have been given some instruction on the method and reason for a regulator.

Air Compressor Running Suggestions

1- Please don’t allow any untrained personnel to operate or interfere in any way with your valuable air compressor.

2- Incoming air for the in-take on the compressor must come from a clean, fresh air source, especially if the air is used for breathing masks. Remember; most compressed air fed masks do NOT protect you from carbon monoxide poisoning.

3- All compressors are built to operate at a defined speed. Never increase or decrease the speed without expert advice.

4- Never allow a compressor to overheat. A 20 hp compressor (15Kw) produces about 5 domestic electrical heaters of power while running, don’t trap this heat, either make use of it or disperse it away from the compressor.

5- If there are moving parts on the compressor that could be touched, put a guard on it, but make sure the compressor is truly isolated before you attempt to touch any moving part.

Compressor Maintenance

It goes without saying; only authorised and trained personnel should be allowed to service or maintain your air compressor and air systems.

1- If they compressor is outside in the open or in a damp area, have an industrial electrician ensure the equipment is well earthed.

2- It is very important that the air compressor is filled with the correct lubricant. A poor lubricant can cause overheating and even start a fire.

3- Disconnect ALL compressors from the electrical power system when servicing your air compressor and if necessary, remove the fuses and tag the isolator. I have known of an instance where the fuses were re-inserted and the tags were removed while the engineer was actually working on the compressor. The engineer now carries the fuses with him in his toolbox!! You can never be too careful when it comes to safe maintenance.

4- If ever you have the need to hire a petrol or diesel driven compressor, say as an emergency stand-by, do not operate it inside your building. Put it outside and make sure the exhaust is not near any windows, fresh air intake or air condition ducting to avoid carbon monoxide poisoning.

5- Never use highly vaporising materials to clean your air compressor, the fumes can be sucked in by the compressor and distributed throughout the premises.

What Type of Oil do you require?

As a rule of thumb, you should use the oil that is recommended in the manual. If it is no longer available, contact the compressor manufacturer/supplier. Don’t rely on the oil distributer. I was once supplied with a compressor oil by one of the most prestigious manufacturers of oil in the world. It ruined two brand new compressors within a week. It was normally a brilliant lubricant for most compressors but had one serious flaw for this newer model, it did not mix with high pressures but instead evaporated on contact and totally failed to lubricate the compressors. If in doubt contact us at Compressed Air Centre, e-mail info@CompressedAirCentre.com. You must use the oil recommended by the compressor manufacturer or you may break the warranty conditions.

Make sure the oil is clearly labelled as Compressor Lubricating Oil. Compressor oil is a special lubricant suitable for the compressor industry only. They usually have additives which are not necessarily found in car oil etc. and may be altered to suit different types and temperatures depending on the compressor make.

If you are using an industrial air compressor continuously, consider changing the oil more often that the manufacturer recommends. For example; if it is sited in a dusty, damp or high temperature environment, change it twice as often as the manual suggests.

With air tools in general, it is advisable that most moving parts require some type of lubrication. The efficiency of cylinders, valves, air motors and most air tools will be greatly improved if they are supplied with adequate lubrication. Most of the pneumatic components are lubricated by using an in-line lubricator, this works by adding lubricating oil in aerosol form into your compressed air line.

The air passes through the lubricator and carries the lubricant to your air tools, cylinders and other pneumatic equipment. The lubricant is deposited on any moving surface to reduce friction and wear. Most lubricators have a set-oil delivery feature which automatically provides a nearly constant oil-to-airflow over a wide range of air usages. A differential is created between the air-line pressure and pressure to the lubricator reservoir. The pressure differential causes oil to be sucked from the reservoir and fed into an outer section where the oil atomises and mixes with the air flowing out to power your pneumatic equipment.

There are several basic types of lubricators. The most popular is the Oil-fog. The Oil-fog type lubricator sends out oil in droplet form and is used with one tool located within a short working distance of the lubricator. The Micro-fog type lubricator sends out a very fine oil mist which can be carried over a much longer distance and can lubricate several tools at any one time.

Lubricators are sized according to your air supply needs downstream. An analysis of your air flow usage should be made. After determining how much air flow is needed, a lubricator can be chosen.

Warning: Always make sure that the lubricants you use are compatible with the materials in the lubricator you install. This is especially important for plastic lubricators. The wrong lubricant could lead to a serious leak or even an explosion. If in doubt, check with your supplier or use a metal reservoir.

When draining your air receiver, try to drain it into some kind of container via a plastic hose. If you notice a lot of oily gunge continually coming from the receiver daily, have your air compressor checked; it may be passing a lot of oil and may need to be serviced. As a general rule, drain the compressor tank after every use.

As soon as you compress air you have water in the tank. If you do not drain it daily it may rust the tank from the inside. A lot of air receivers coming from Asia are made from poor materials. The culture of “safety” does not exist for most suppliers in this part of the world so; Drain your tank daily and slow down the eventual rust that will happen with every low cost compressor air tank.

Where possible, leave your tank drain open until you go to use the air compressor again. Do not forget to close the drain when you next go to use your compressor. Some compressors are very loud so you may not hear the air escaping through the drain. Zero Air Loss Drain Valves are safer and more economical.

Getting the correct size of air compressor is not that complex if you know exactly what you are doing. But some people buy their air compressor without considering how big an air compressor they are really going to need to run their air tools etc.

You need to find out the compressed air requirement for all the air tools, all the blow guns, all the air cylinders and all other equipment requiring air. See “What Size of Compressor Do I need” on the lower left-hand side of our home page on our website for some assistance. If you need further help will you please ring us at 041-9836923 or e-mail infor@CompressedAirCentre.com

If you have a business that requires continued compressed air all day long and your air compressor cannot keep up with demand, call us and we will do an air audit on your air system to assess what needs to be done to correct your system (unless of course it just needs a service urgently).

Compressed air consumption of your air tools varies, depending on the size of the air tool, it’s usage, and the efficiency of that air tool. You need to get the specific compressed air demand for that air tool from the manual or the supplier. Running your business with an undersized compressor can be very expensive in the long run.

Production equipment using valves, air cylinders, air actuators and other pneumatic equipment might run for 2 or 3 shifts per day. Therefore each shift may have different air demands. This should also be a major consideration when installing or updating your compressed air equipment.

Cylinder and Valve Air Consumption

The manufacturer of any of your air equipment should be able to provide you with specifications for their machinery. They know how many cylinders etc. are required to operate their equipment and at what rate. They should be able to provide you with all the information about air consumption for your own purposes. Ask for it.

If you are having any difficulty assessing the compressed air usage of a particular piece of equipment (something you have made yourself for example), go to our website and request our Compressed Air Manual. There is a simple guide in it which will help you through the use of your air receiver.

When you buy an air compressor, always ask what the “free air delivery” is. This figure is necessary in order to work out your air tool requirements. Most piston compressors are rated in “displacement” figures; this is useless for determining your air requirements. For example; a poor quality 3 hp air compressor may be rated at 15 cfm displacement but the actual air it produces (free air delivery FAD) may be as little as 4 FAD when the compressor has only ran for a short period, especially after it “heats up”.

A well-built air compressor of decent quality should give approx. 75% of it’s displacement figure in FAD at 10 bar.

(Air delivery figures for lower pressures (ie 5bar) is higher than the delivery figures from the same air compressor at 10bar.)

A compressor might show a CFM rating of 8 for example, but reading the fine print will tell you that it generates 8 CFM at a much lower pressure rating than the pressure you may require.

Most air equipment requires at least 90 PSI (6 bar) to work to it’s capacity. Some will require higher pressure, and some lower.

When choosing an air compressor either to upgrade your old unit or moving to a new premises you must consider many factors:

If , when choosing to go for a larger compressor, you discover that your power supply comes only in 220 volts then you must consider the following; either you have your power supplier install 3 phase power 400/440 volts or go for a tandem air compressor. We can supply a very special, heavy duty tandem compressor that includes “low voltage” start-up combined with the largest supply of Free Air Delivery (FAD) for that size (3 x 3 hp) on the market.

Remember; if you’re running a business then the last thing you need is a compressor that cannot supply the volume of compressed air your air tools require i.e. your air compressor cannot keep up with your air tool demand and runs low on compressed air and pressure.

When you require a new compressor or a larger compressor, your potential supplier should be asking you about all the equipment you use and might use in the future. They should also discuss tank (air receiver) size, power supply, site installation (where necessary), warranty, pressure, service and parts availability (are either of these provided by the supplier DIRECTLY?) Do they do contract long term service, can they supply a number of genuine references, if there is a warranty issue, and how soon will they take to fix it? Can they supply a replacement compressor if urgently required, and so on?

It is worth repeating and reminding you about your air compressor security once again; the last thing you need is for you or your staff standing around just because someone untrained has tampered with you air compressor.

Do Not allow unknowledgeable personnel tamper or adjust your compressor. If it is in a shed outside your work premises, lock the shed. That way you at least know that if the compressor stops for any reason, there is nobody to blame. Apart from the danger aspect of compressed or pressurised air, keep your air compressor out of bounds to all except those who know what they’re doing. But please remember when you lock the door, make sure the air compressor has plenty of cool ventilation and there is lots of room for servicing it.

Also please remember that the compressor needs to be kept cool so don’t have it sited near a boiler or any other equipment that produces heat. Look at the kilowatt of the compressor motor; if it says 20 kW then that is in or near the amount of heat it is producing. So either utilise the heat or disperse it away from the air intake filter. Try and use the heat, otherwise it’s a terrible waste.

Waste Heat Recycling

There are several ways of using the heat generated by a large air compressor; you could have it ducted into your work area, yet making sure you can re-divert it during the warm weather. You could install the compressor in the warehouse (installing it in the warehouse or similar scenario is good because the heat generated doesn’t normally affect the general temperature to the same degree that it might do in a working or productive area). In other words; the higher temperatures in the summer may not be noticeable. In certain instances, the heat can be used to heat water or other liquids via an after-cooler type of system.

Of course it goes without saying that; if installed in a warehouse atmosphere, make sure the compressor has plenty of cool air circulating around it. It is also worth remembering that the higher the air intake temperature is, the greater the cost of producing each cubic foot of compressed air.

Compressor Generated Water

It is very important to reduce the amount of moisture that enters your compressed air system or pneumatic equipment. However, it can be very expensive if you are removing vapour unnecessarily.

The moisture content in your compressed air is usually referred to as the “pressurised dew point” (it is important it states the word “pressurised”). 80% of industry work perfectly well on +4 degree Celsius Pressurised dew point. If that is all you need and if there is no moisture causing problems with your work then you probably have the conventional air dryer. This is called a “refrigerant” dryer and is the most common. Should you require -10 degree Celsius dew point or greater (i.e. minus 70 Celsius) then you will need a desiccant dryer.

(Your compressor may produce up to 1500 litres of water per annum).

The following are just some of the problems created by moisture in your compressed air system and not having the correct moisture removing options.

Fish Eyes (in car spraying for example),

Instruments failing to operate accurately,

Moisture affecting the quality and taste of food products etc.

Contaminants in food products

Valves and cylinders sticking or jamming,

Air tools slowing down and underperforming

http://www.compressedaircentre.com/product-category/air-dryers/

Please request our Free “Compressor Manual” for much more information which is available only from the author; Compressed Air Centre Ltd.

Please note; we are also the author of “Compressed Air Safety Manual” that, as far as we know, is the only one available worldwide, Brian.